A novel organic-inorganic hybrid flame retardant consisting of a brucite core and a dodecylamine polyphosphate shell was synthesized by a facile nanoengineering route. The flammability characterization and synergistic flame retardant mechanism of the core/shell flame retardant (CFR) in ethylene-vinyl acetate (EVA) blends had been compared with EVA/physical mixture (PM, with the given proportion of brucite and dodecylamine polyphosphate as well as CFR) and EVA/brucite blends. With the same loading amount (40 wt%) of fillers in EVA, the peak heat release rate and smoke production rate of EVA/CFR blends were significantly reduced to 49% and 48% of that of EVA/PM blends, respectively. Meanwhile, the limiting oxygen index (LOI) was increased up to 32 (14.3% higher than that of EVA/PM blends) and the UL-94 test could achieve the V-0 rating. These remarkable properties were obtained just by nanoengineeing the core/shell structured brucite@polyphosphate@amine hybrid system, facilitating the formation of intact and compact residue with fence structure in process of polymer composite burning.

A novel and efficient halogen-free composite flame retardant (CFR) consisting of a brucite core and a fine zinc borate [Zn6O(OH)(BO3)3] hierarchical nanostructure shell was designed and synthesized via a facile nanoengineering route. It had been demonstrated that this unique hybrid structure possessed a high BET specific surface area (65 m2/g) and could significantly enhance the interfacial interaction when mixing with ethylene-vinyl acetate (EVA). This improved the transfer of stress between CFR particles and EVA matrix and increased the viscosity of EVA/EVA blends, which was beneficial for droplet inhibition and char forming. The mechanical properties and flammability behaviors of the EVA/CFR blends had been compared with the EVA/physical mixture (PM, with the given proportion of brucite and Zn6O(OH)(BO3)3). The mechanical properties of EVA/CFR blends, especially the tensile strength (TS), presented a remarkable increase reaching at least a 20% increment. Meanwhile, with the same 45 wt % of fillers, the EVA/CFR formulation could achieve a limiting oxygen index (LOI) value of 33 (37.5 % higher than that of EVA/PM blends) and UL-94 V-0 rating. Moreover, the heat release rate (HRR), peak heat release rate (PHRR), total heat released (THR), smoke production rate (SPR) and mass loss rate (MLR) were considerably reduced, especially PHRR and SPR for EVA/CFR blends were reduced to 32%. According to this study, the design of fine structure might pave the way for the future development of halogen-free flame retardants combining both enhanced mechanical properties and excellent flame retardant behaviors.Keywords: brucite; flame retardant; hierarchical structure; interfacial interaction; mechanical properties; zinc borate;